Ultraviolet radiation protection of composite panel and method of making and using the same

ABSTRACT

A number of variations may include a product including a composite panel comprising a substrate comprising a fiber weave, and a first layer overlying the substrate comprising silicone wherein the composite panel is constructed and arranged to resist ultraviolet radiation.

TECHNICAL FIELD

The field to which the disclosure generally relates to includes composite panels including, but not limited to, coatings and panels for vehicles.

BACKGROUND

In a number of variations, vehicle panels may include coating layers that provide Ultraviolet (UV) radiation protection.

SUMMARY OF ILLUSTRATIVE VARIATIONS

A number of variations may include a product which may include: a composite panel comprising a substrate comprising a fiber weave, and a first layer overlying the substrate comprising silicone wherein the composite panel is constructed and arranged to resist ultraviolet radiation.

A number of variations may include a method which may include: providing a substrate comprising a fiber weave; and depositing a first layer over the substrate comprising silicone to provide a composite panel constructed and arranged to resist ultraviolet radiation.

Other illustrative variations within the scope of the invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while disclosing variations within the scope of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Select examples of variations within the scope of the invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is a view of a product according to a number of variations.

FIG. 2A is a view of a product according to a number of variations.

FIG. 2B is a view of a product according to a number of variations.

FIG. 2C is a view of a product according to a number of variations.

FIG. 3 is a method according to a number of variations.

DETAILED DESCRIPTION OF ILLUSTRATIVE VARIATIONS

The following description of the variations is merely illustrative in nature and is in no way intended to limit the scope of the invention, its application, or uses.

FIG. 1 illustrates a product 10 according to a number of variations. In a number of variations, the product 10 may include a composite panel 12. In a number of variations, the composite panel 12 may include a substrate 14. In a number of variations, the substrate 14 may include a fiber weave 40. In a number of variations, the substrate 14 may include carbon fiber weave. In a number of variations, the composite panel 12 may include a first layer 16 overlying the substrate 14. In a number of variations, the first layer 16 may include silicone. In a number of variations, the first layer may include at least one of a primer 32 or a hard coat 34. In a number of variations, the composite panel 12 may include a second layer 18 overlying the first layer 16. In a number of variations, the second layer 18 may include a clear coat. In a number of variations, the second layer 18 may overlie the substrate 14 and underlie the first layer 16. In a number of variations, the composite panel 12 may include a plurality of layers of the first layer 16 and/or second layer 18 in any orientation overlying or underlying each other. In a number of variations, the second layer 18 may lie between the first layer 16 and the substrate 14. In a number of variations, additional layers may lie on the composite panel 12 overlying the substrate 14 and oriented overlying or underlying the first layer 16 and/or the second layer 18. In a number of variations, the composite panel 12 may be constructed and arranged to resist ultraviolet (UV) radiation. In a number of variations, the composite panel 12 may be an exterior panel for a vehicle. In a number of variations, the composite panel 12 may be used as, but is not limited to, an underwater panel, a pigment stability panel, an emblem panel, a spoiler, a car door, a car hood, a side panel, a bumper, a rear panel, a headlight, or may be used in another way. In a number of variations, the vehicle may include a motor vehicle, watercraft, spacecraft, aircraft, or may be another type.

In a number of variations the substrate 14 may be a fiber weave 40. In a number of variations, the fiber weave 40 may include a carbon fiber weave. In a number of variations, the substrate 14 may include a plurality of fibers. In a number of variations, the fibers may be textile, natural or synthetic or may be another type. In a number of variations, the fibers in the fiber weave 40 may include animal, vegetable, or mineral fibers including, but not limited to, alpaca, angora, byssus, camel hair, cashmere, catgut, chiengora, guanaco, llama, mohair, pashmina, qiviut, rabbit, silk, sinew, spider silk, wool, vicuna, yak, abaca’, bagasse, bamboo, coir, cotton, flax, hemp, jute, kapok, kenaf, pina, raffia, ramie, sisal, wood, asbestos, acetate, triacetate, art silk, lyocell rayon, silica, modal rayon, rayon, glass, carbon, basalt, metallic, acrylic, aramid (including Twaron, Kevlar, Technora, Nomex), microfiber, modacrylic, nylon, olefin, polyester, polyethylene, spandex, vinylon, vinyon, zylon, saran, carbon-fiber-reinforced polymer, carbon-fiber-reinforced plastic, carbon-fiber reinforced thermoplastic, or carbon nanotube reinforced polymer, fiber reinforced polymer, fiberglass (including E-glass, A-glass, E-CR-glass, C-glass, D-glass, R-glass, and S-glass, or may be another type), basalt, aluminum, or may be another type. In a number of variations, the substrate 14 or fiber weave 40 may contain combinations of the above in varying concentrations and the components may be intermixed. In a number of variations, the substrate 14 may be formed by sheets, continuous mats, or as continuous filaments. In a number of variations, the substrate 14 or fiber weave 40 may be formed using a hand lay-up operation, a spray lay-up operation, a pultrusion operation, a chopped strand mat, vacuum bag moulding, pressure bag moulding, autoclave moulding, resin transfer moulding, vacuum assisted resin transfer moulding, bladder moulding, compression moulding, mandrel wrapping, wet layup, chopper gun, filament winding, melting, staple fiber, continuous filament, or may be formed another way. In a number of variations, the substrate 14 or fiber weave 40 may be manufactured in a two dimensional or three dimensional orientation. In a number of variations, the substrate 14 or fiber weave 40 may include short-fiber reinforced materials or continuous fiber-reinforced materials or may include another type. In a number of variations, the substrate 14 or fiber weave 40 may be manufactured or woven through weaving, knitting, braiding, stitching, plain weaving, satin weaving, or may be manufactured in another way. In a number of variations, the substrate 14 or fiber weave 40 may have various widths, lengths and/or diameters of fibers as well as in its overall dimensions. In a number of variations, the substrate 14 or fiber weave 40 may be preimpregnated, coated, or otherwise in contact with a bonding agent 80.

In a number of variations, the first layer 16 may include a primer 30. In a number of variations, at least one of the first layer 16 or primer 30 may include diacetone alcohol in a weight percentage of approximately 10%≧x≧30%. In a number of variations, at least one of the first layer 16 or primer may include 1-methoxy-2-propanol in a weight percentage of approximately 60%≧x≧90%; in a number of variations, the weight percentage may be approximately 65%≧x≧85%; in a number of variations, the weight percentage may be approximately 70%≧x≧80%; in a number of variations, the weight percentage may be approximately 72%≧x≧78%; or any range therebetween. In a number of variations, at least one of the first layer 16 or primer 30 may include dibenzoylresorcine in a weight percentage of approximately 1%≧x≧5%; in a number of variations, the weight percentage may be approximately 1.5%≧x≧4.5%; in a number of variations, the weight percentage may be approximately 2%≧x≧4%; in a number of variations, the weight percentage may be approximately 2.5%≧x≧3.5%; or any range therebetween. In a number of variations, at least one of the first layer 16 or primer 30 may include polymethyl methacrylate in a weight percentage of approximately 5%≧x≧10%; in a number of variations, the weight percentage may be approximately 5.5%≧x≧9.5%; in a number of variations, the weight percentage may be approximately 6%≧x≧9%; in a number of variations, the weight percentage may be approximately 7%≧x≧8%; or any range therebetween. In a number of variations, a plurality of layers of the primer 30 may be used in the first layer 16. In a number of variations, the first layer 16 or primer 30 may be applied to or deposited on the substrate 14 or other layer of the composite panel 12 through dip coating, spray coating, flow coating, painting, or may be applied or deposited a different way. In a number of variations, the thickness of the primer 30 may be about 1.0 μm≧x≧10.0 μm.

In a number of variations, the first layer 16 may include a hard coat 32. In a number of variations, at least one of the first layer 16 or hard coat 30 may include methanol in a weight percentage of approximately 10%≧x≧30%; in a number of variations, the weight percentage may be approximately 12%≧x≧27%; in a number of variations, the weight percentage may be approximately 15%≧x≧25%; in a number of variations, the weight percentage may be approximately 17%≧x≧23%; or any range therebetween. In a number of variations, at least one of the first layer 16 or primer 30 may include n-butanol in a weight percentage of approximately 10%≧x≧30%; in a number of variations, the weight percentage may be approximately 12%≧x≧27%; in a number of variations, the weight percentage may be approximately 15%≧x≧25%; in a number of variations, the weight percentage may be approximately 17%≧x≧23%; or any range therebetween. In a number of variations, at least one of the first layer 16 or hard coat 30 may include 2-propanol in a weight percentage of approximately 10%≧x≧30%; in a number of variations, the weight percentage may be approximately 12%≧x≧27%; in a number of variations, the weight percentage may be approximately 15%≧x≧25%; in a number of variations, the weight percentage may be approximately 17%≧x≧23%; or any range therebetween. In a number of variations, at least one of the first layer 16 or hard coat 30 may include acetic acid in a weight percentage of approximately 1%≧x≧5%; in a number of variations, the weight percentage may be approximately 1.5%≧x≧4.5%; in a number of variations, the weight percentage may be approximately 2%≧x≧4%; in a number of variations, the weight percentage may be approximately 2.5%≧x≧3.5%; or any range therebetween. In a number of variations, at least one of the first layer 16 or hard coat 30 may include 1-methoxy-2-propanol in a weight percentage of approximately 1%≧x≧5%; in a number of variations, the weight percentage may be approximately 1.5%≧x≧4.5%; in a number of variations, the weight percentage may be approximately 2%≧x≧4%; in a number of variations, the weight percentage may be approximately 2.5%≧x≧3.5%; or any range therebetween. In a number of variations, at least one of the first layer 16 or hard coat 30 may include modified silicone resin in a weight percentage of approximately 10%≧x≧30%; in a number of variations, the weight percentage may be approximately 12%≧x≧27%; in a number of variations, the weight percentage may be approximately 15%≧x≧25%; in a number of variations, the weight percentage may be approximately 17%≧x≧23%; or any range therebetween. In a number of variations, at least one of the first layer 16 or hard coat 30 may include water in a weight percentage of approximately 10%≧x≧30%; in a number of variations, the weight percentage may be approximately 12%≧x≧27%; in a number of variations, the weight percentage may be approximately 15%≧x≧25%; in a number of variations, the weight percentage may be approximately 17%≧x≧23%; or any range therebetween. In a number of variations, the hard coat 32 may comprise the entirety of the first layer 16. In a number of variations, a plurality of layers of the hard coat 32 may be used in the first layer 16. In a number of variations, the first layer 16 may include a plurality of layers of the hard coat 32 and primer 30 in any orientation overlying or underlying each other. In a number of variations, the first layer 16 or hard coat 32 may be applied to or deposited on the substrate 14 or other layer of the composite panel 12 through dip coating, spray coating, flow coating, painting, or may be applied or deposited a different way. In a number of variations, the thickness of the hard coat 32 may be about 1.0 μm≧x≧10.0 μm.

In a number of variations, the second layer 18 may include a clear coat 50. In a number of variations, at least one of the second layer 18 or clear coat 50 may include heptan-2-one in a weight percentage of approximately 10%≧x≧25%; in a number of variations, the weight percentage may be approximately 12%≧x≧22%; in a number of variations, the weight percentage may be approximately 15%≧x≧20%; in a number of variations, the weight percentage may be approximately 17%≧x≧19%; or any range therebetween. In a number of variations, at least one of the second layer 18 or clear coat 50 may include acetic acid hexyl ester in a weight percentage of approximately 10%≧x≧25%; in a number of variations, the weight percentage may be approximately 12%≧x≧22%; in a number of variations, the weight percentage may be approximately 15%≧x≧20%; in a number of variations, the weight percentage may be approximately 17%≧x≧19%; or any range therebetween. In a number of variations, at least one of the second layer 18 or clear coat 50 may include n-butyl acetate in a weight percentage of approximately 5%≧x≧10%; in a number of variations, the weight percentage may be approximately 6%≧x≧9%; in a number of variations, the weight percentage may be approximately 7%≧x≧8%; in a number of variations, the weight percentage may be approximately 7.2%≧x≧7.8%; or any range therebetween. In a number of variations, at least one of the second layer 18 or clear coat 50 may include 2-butoxyethyl acetate in a weight percentage of approximately 1%≧x≧5%; in a number of variations, the weight percentage may be approximately 1.5%≧x≧4.5%; in a number of variations, the weight percentage may be approximately 2%≧x≧4%; in a number of variations, the weight percentage may be approximately 2.5%≧x≧3.5%; or any range therebetween. In a number of variations, at least one of the second layer 18 or clear coat 50 may include Poly(oxy-1,2-ethanediyl), .alpha.-[3-[3-(2H-benzotriazol-2-yl)-5-(1,1dimethylethyl)-4-hydroxyphenyl]-1-oxopropyl].omega.-hydroxy- in a weight percentage of approximately 1%≧x≧5%; in a number of variations, the weight percentage may be approximately 1.5%≧x≧4.5%; in a number of variations, the weight percentage may be approximately 2%≧x≧4%; in a number of variations, the weight percentage may be approximately 2.5%≧x≧3.5%; or any range therebetween. In a number of variations, the clear coat 50 may comprise the entirety of the second layer 18. In a number of variations, the second layer 18 or clear coat 50 may be applied to or deposited on the substrate 14 or other layer of the composite panel 12 through dip coating, spray coating, flow coating, painting, or may be applied or deposited a different way. In a number of variations, the thickness of the clear coat 50 may be about 25 μm≧x≧75 μm.

Still referring to FIG. 1, in a number of variations a bonding agent 80 may be held in contact with the substrate 14, first layer 16, or second layer 18. In a number of variations, this contact may result in adherence or bonding between the bonding agent 80, the substrate 14, first layer 16, or second layer 18, or any combination thereof. In a number of variations, the bonding agent 80 may include urethane resin, vinylester resin, polyester resin, epoxy resin, phenolic resin, modified phenolic resin or may be another type. In a number of variations, the bonding agent 80 may be reactive or non-reactive. In a number of variations, the bonding agent 80 may be applied to or deposited on the substrate 14, first layer 16 or second layer 18 or another layer of the composite panel 12 through dip coating, spray coating, flow coating, painting, or may be applied or deposited a different way.

FIGS. 2A-2C show the product 10 according to a number of variations. In a number of variations, the product 10 may include the hard coat 32. In a number of variations, the hard coat 32 comprising silicone may provide UV resistance beyond existing hard coats. In a number of variations, as shown in FIG. 2A, the hard coat 32 may exhibit a higher gloss percentage at higher exposures than existing hard coats. In a number of variations, as shown in FIG. 2B, the hard coat 32 may exhibit a lower change in energy at higher exposures than existing hard coats. In a number of variations, as shown in FIG. 2C, the hard coat 32 may exhibit a slower decrease in adhesion at higher exposures than existing hard coats. In a number of variations, the composite panel 12 with the hard coat 32 may exhibit enhanced UV resistance at a lower cost than existing hard coats or clear coats.

FIG. 3 shows a method 800 according to a number of variations. In a number of variations, the method 800 may include in block 802 providing a substrate 14 comprising a fiber weave 40. In a number of variations, the method 800 may further include, in block 804, depositing a first layer 16 over the substrate 14 comprising silicone to provide a composite panel 12 constructed and arranged to resist ultraviolet radiation. In a number of variations, the method 800 may further include, in block 806, depositing a second layer 18 comprising a clear coat 50 over the first layer 16. In a number of variations, the method 800 may further include, in block 808, depositing a second layer 18 comprising a clear coat 50 between the first layer 16 and the substrate 14. In a number of variations, the method 800 may further include, in block 810, depositing additional layers on the composite panel 12. FIG. 3 shows a method 900 according to a number of variations. In a number of variations, the method 900 may include in block 902 providing a substrate 14 comprising a fiber weave 40. In a number of variations, the method 900 may further include, in block 904, depositing a second layer 18 comprising a clear coat 50 over the substrate 14. In a number of variations, the method 900 may further include, in block 906, depositing a first layer 16 comprising silicone over the second layer 18 to provide a composite panel 12 constructed and arranged to resist ultraviolet radiation. In a number of variations, the method 900 may further include, in block 908, depositing additional layers on the composite panel 12.

The following description of variants is only illustrative of components, elements, acts, product and methods considered to be within the scope of the invention and are not in any way intended to limit such scope by what is specifically disclosed or not expressly set forth. The components, elements, acts, product and methods as described herein may be combined and rearranged other than as expressly described herein and still are considered to be within the scope of the invention.

Variation 1 may include a product that may include a composite panel comprising a substrate comprising a fiber weave, and a first layer overlying the substrate comprising silicone wherein the composite panel is constructed and arranged to resist ultraviolet radiation.

Variation 2 may include a product as set forth in Variation 1 wherein the first layer comprises a hard coat comprising modified silicone resin.

Variation 3 may include a product as set forth in any of Variations 1-2 wherein the fiber weave comprises carbon fiber.

Variation 4 may include a product as set forth in any of Variations 1-3 wherein the composite panel further comprises a second layer comprising a clear coat.

Variation 5 may include a product as set forth in any of Variations 2-4 wherein the first layer further comprises a primer.

Variation 6 may include a product as set forth in Variation 5 wherein the primer comprises dibenzoylresorcine.

Variation 7 may include a product as set forth in any of Variations 1-6 wherein the composite panel is an exterior panel for a vehicle.

Variation 8 may include a product as set forth in any of Variations 4-7 wherein the second layer lies between the first layer and the substrate.

Variation 9 may include a product as set forth in any of Variations 4-8 wherein the second layer overlies the first layer.

Variation 10 may include a product as set forth in any of Variations 4-9 wherein the clear coat comprises acetic acid hexyl ester.

Variation 11 may include a method that may include providing a substrate comprising a fiber weave; and depositing a first layer over the substrate comprising silicone to provide a composite panel constructed and arranged to resist ultraviolet radiation.

Variation 12 may include method as set forth in Variation 11 wherein the first layer comprises a hard coat comprising modified silicone resin.

Variation 13 may include a method as set forth in any of Variations 11-12 wherein the fiber weave comprises carbon fiber.

Variation 14 may include a method as set forth in any of Variations 11-13 wherein the method further comprises depositing a second layer comprising clear coat over the first layer.

Variation 15 may include a method as set forth in any of Variations 12-14 wherein the first layer further comprises a primer.

Variation 16 may include a method as set forth in Variation 15 wherein the primer comprises dibenzoylresorcine.

Variation 17 may include a method as set forth in any of Variations 11-16 wherein the composite panel is an exterior panel for a vehicle.

Variation 18 may include a method as set forth in any of Variations 11-17 wherein the method further comprises depositing a second layer between the first layer and the substrate.

Variation 19 may include a method as set forth in any of Variations 11-18 wherein the hard coat further comprises 1-methoxy-2-propanol.

Variation 20 may include a method as set forth in any of Variations 11-19 wherein the clear coat comprises acetic acid hexyl ester.

The above description of select variations within the scope of the invention is merely illustrative in nature and, thus, variations or variants thereof are not to be regarded as a departure from the spirit and scope of the invention. 

1. A product comprising: a composite panel comprising a substrate comprising a fiber weave, and a first layer overlying the substrate comprising silicone wherein the composite panel is constructed and arranged to resist ultraviolet radiation.
 2. The product as set forth in claim 1 wherein the first layer comprises a hard coat comprising modified silicone resin.
 3. The product as set forth in claim 1 wherein the fiber weave comprises carbon fiber.
 4. The product as set forth in claim 1 wherein the composite panel further comprises a second layer comprising a clear coat.
 5. The product as set forth in claim 2 wherein the first layer further comprises a primer.
 6. The product as set forth in claim 5 wherein the primer comprises dibenzoylresorcine.
 7. The product as set forth in claim 1 wherein the composite panel is an exterior panel for a vehicle.
 8. The product as set forth in claim 4 wherein the second layer lies between the first layer and the substrate.
 9. The product as set forth in claim 4 wherein the second layer overlies the first layer.
 10. The product as set forth in claim 4 wherein the clear coat comprises acetic acid hexyl ester.
 11. A method comprising: providing a substrate comprising a fiber weave; and depositing a first layer over the substrate comprising silicone to provide a composite panel constructed and arranged to resist ultraviolet radiation.
 12. The method as set forth in claim 11 wherein the first layer comprises a hard coat comprising modified silicone resin.
 13. The method as set forth in claim 11 wherein the fiber weave comprises carbon fiber.
 14. The method as set forth in claim 11 wherein the method further comprises depositing a second layer comprising a clear coat over the first layer.
 15. The method as set forth in claim 12 wherein the first layer further comprises a primer.
 16. The method as set forth in claim 12 wherein the primer comprises dibenzoylresorcine.
 17. The method as set forth in claim 11 wherein the composite panel is an exterior panel for a vehicle.
 18. The method as set forth in claim 11 wherein the method further comprises depositing a second layer between the first layer and the substrate.
 19. The method as set forth in claim 14 wherein the hard coat further comprises 1-methoxy-2-propanol.
 20. The method as set forth in claim 14 wherein the clear coat comprises acetic acid hexyl ester. 